Concurrent, layer-by-layer powder and mold fabrication for multi-functional parts

Abstract

The present disclosure provides for a method of making a part using powder metallurgy and material extrusion. The method includes forming a mold of a first material using material extrusion. The method includes depositing a second material within the mold. The second material is deposited as a powder. The method includes compacting the second material within the mold, and heating the mold and the second material within the mold. During the heating, the mold is separated from the material by melting, evaporating, or burning of the first material, and the second material is sintered. Also provided for are parts made by the method and a system for making such parts. The system includes a material extrusion head and a powder deposition head. Each head is articulable along three axes.

What is claimed is: 
     
       1. A method of making a part using powder metallurgy and material extrusion, the method comprising:
 forming a mold of a first material using material extrusion; 
 depositing a second material within the mold, wherein the second material is deposited into the mold in powder form; 
 compacting the second material within the mold; 
 heating the mold and the second material within the mold, wherein, during the heating the mold is separated from the second material by melting, evaporating, burning, or combinations thereof of the first material, and wherein during the heating the second material is sintered; and 
 obtaining a part. 
 
     
     
       2. The method of  claim 1 , the sintering includes hot isostatic pressing. 
     
     
       3. The method of  claim 1 , wherein the first material melts, evaporates, burns, or combinations thereof at a lower temperature than the temperature at which the second material sinters. 
     
     
       4. The method of  claim 1 , wherein the first material is a polymer resin, and wherein second material is a metal powder, a metal alloy powder, a ceramic powder, or combinations thereof. 
     
     
       5. The method of  claim 1 , wherein the method includes extruding the first material from at least one extrusion head to form the mold, and depositing the second material from at least one deposition head into the mold. 
     
     
       6. The method of  claim 5 , wherein the method includes articulating the at least one extrusion head along three axes during extrusion of the first material, and articulating the at least one deposition head along three axes during deposition of the second material. 
     
     
       7. The method of  claim 1 , wherein the forming of the mold and the deposition of the second material are performed concurrently. 
     
     
       8. The method of  claim 7 , wherein the method includes concurrent extrusion of the first material and deposition of the second material, including extruding the first material to form the mold while simultaneously depositing the second material into formed portions of the mold. 
     
     
       9. The method of  claim 7 , wherein the method includes concurrent extrusion of the first material and deposition of the second material, including sequential cycles of extrusion of the first material to form a portion of the mold and deposition of the second material into the formed portion of the mold. 
     
     
       10. The method of  claim 1 , wherein the mold is formed layer-by-layer and the second material is deposited layer-by-layer, including:
 extruding first layer of the first material to form a first portion of the mold; 
 depositing a first portion of the second material within the first portion of the mold; 
 extruding second layer of the first material to form a second portion of the mold; and 
 depositing a second portion of the second material within the second portion of the mold. 
 
     
     
       11. The method of  claim 1 , wherein the part is at least partially degradable, and wherein the second material is a degradable material. 
     
     
       12. The method of  claim 1 , the part is a smart part, and wherein the second material is a smart material. 
     
     
       13. The method of  claim 1 , wherein the part is a cutting bit, a piezoelectric sensing pars, a composite part, a graded material part, an axial pulse generator, a drill bit, a bearing, an impeller/diffuser, a turbine, a flow diverter, a bushing, a thrust washer, a rotor, a stator, a blender, a mixer, a gear, a cam, a pump stage, a shaft, a sleeve, a wear band, a pad, a stabilizer, a centralizer, a collar, a fastener, a threaded ring, a valve seat, an insert, a seal, a sucker rod, a collet, an anchor, a mandrel, a housing, a tubular, a protector, a connector, a ferrule, a pin, a nozzle, a screen, a filter, or a heat exchanger. 
     
     
       14. The method of  claim 1 , wherein a third material is deposited into the mold, and wherein the second material and the third material exhibit different properties. 
     
     
       15. The method of  claim 14 , wherein the third material is deposited in a different position within the mold than the second material. 
     
     
       16. A method of making a part using powder metallurgy and material extrusion, the method comprising:
 forming a mold of a first material by extruding the first material; 
 depositing a second material into the mold, wherein multiple layers of the second material are deposited in the form of a powder; 
 heating the mold and the second material within the mold, wherein, during the heating the mold is separated from the second material by melting, evaporating, burning, or combinations thereof of the first material; 
 after the mold is separated from the second material, increasing pressure and temperature on the second material, wherein during the heating the second material is sintered; and 
 obtaining a part, the part comprising the second material. 
 
     
     
       17. The method of  claim 16 , wherein depositing the second material into the mold comprises:
 depositing a first layer of the second material in powder form into the mold; and 
 depositing a second layer of the second material in powder form into the mold, wherein the second layer is deposited onto the first layer. 
 
     
     
       18. The method of  claim 1 , wherein the second material is deposited from a hopper into the mold. 
     
     
       19. The method of  claim 1 , wherein, after the mold is separated from the second material, pressure and temperature on the second material are increased. 
     
     
       20. A method of making a part using powder metallurgy and material extrusion, the method comprising:
 extruding a first material into the form of a mold; 
 depositing a particulate, in powder form, into the mold, wherein the particulate is a metal or ceramic powder; 
 compacting the metal or ceramic powder within the mold; 
 heating the mold and the metal or ceramic powder within the mold, wherein, during the heating the mold is separated from the metal or ceramic powder by melting, evaporating, burning, or combinations thereof of the first material, and wherein during the heating the metal or ceramic powder is sintered; and 
 obtaining a part, the part comprising the sintered metal or ceramic powder.